I have a 2008 S40 with a bad condenser. I have purchased two condensers from local auto parts stores. Each one had the had the same issue. Although they look correct, the manifold assembly that the lines connect to are slightly different and will not connect. Has anyone had this issue? Any advice? I need to get this car back together soon as this is the wife's daily driver and she is getting upset!

 

I replaced mine on a 2005. I remember there being some fitment issues but I got it to work and it has been perfect ever since (to my surprise). Can you post a picture of your problem? You are talking about the aluminum block with the 2 large o-rings and the single bolt holding the block together?

Is it possible to silver solder the old onto the new condensor? I've had fuel lines done for me using this method but not a/c lines. Just throwing out ideas.